23/05/2024 08:12:36

Inverter Air Leak Test (In Vehicle)

Correction code 40202020 0.55 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Procedure

  1. Inspect the condition of the leak test adapter O-ring, and replace if damaged, loose, or missing.
  2. Inspect the condition of the leak test adapter O-ring, and replace if damaged, loose, or missing.
  3. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Disconnect LV power. See LV Power (Disconnect and Connect).
  6. Set the high voltage multimeter to DC voltage, lightly touch the probes to the auxiliary battery connector contacts, and verify that the multimeter displays a voltage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery voltage is typically 14.5 to 15.5 volts.
  7. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  8. If performing the air leak test on the front drive unit inverter, remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  9. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the leather glove protectors and HV insulating gloves.
  11. Press the locking tab, disconnect the rear subframe electrical harness from the drive unit inverter logic connector, and move the electrical harness aside.
  12. Install the leak test adapter plug into the drive unit inverter logic connector.
  13. Slide the red connector locking tab, open the black release lever, and then disconnect the drive unit HV harness from the drive unit inverter HV header.
  14. Install the leak test adapter onto the drive unit inverter HV header.
  15. Connect the enclosure leak tester hose to the leak test adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Restrain the enclosure leak tester hose so that it will not tug the leak test adapter off of the drive unit inverter HV header.
  16. Turn valve P2 (left) and valve P1 (right) to the closed (vertical) position on the enclosure leak tester.
  17. Turn the knob on the regulator to the fully closed setting.
  18. Connect the supply compressed air line to the enclosure leak tester.
  19. Turn valve P1 (right) to the open (horizontal) position and slowly adjust the regulator so that 1 psi is displayed on the gauge.
  20. Slowly turn valve P2 (left) to the open (horizontal) position and allow air to enter the drive unit inverter.
  21. Allow 45 seconds for the pressure to stabilize.
  22. Turn valve P1 (right) to the close (vertical) position.
  23. Record the beginning pressure value and start a 60 second timer.
  24. After 60 seconds has elapsed, record the end pressure value, and then substract the end pressure value from the beginning pressure value: the acceptable pressure difference is 0.2 psi or less.
    • If the pressure difference is 0.2 psi or less, continue the procedure.
    • If the pressure difference is more than 0.2 psi, inspect the drive unit inverter for leaks, check the hose, adapter, and plug fittings, turn valve P2 (left) to the close (vertical) position, turn valve P1 (right) to the open (horizontal) position, check the regulator pressure and retest from step 19. If the difference is still more than 0.2 psi, refer to Toolbox article 6415200 (Tesla Internal) or 6415200 (External parties).
  25. Disconnect the supply compressed air line from the enclosure leak tester.
  26. Slowly turn valve P1 (right) to the open (horizontal) position, and allow air to exit the drive unit inverter.
  27. Disconnect the enclosure leak tester hose from the leak test adapter.
  28. Remove the leak test adapter from the drive unit inverter HV header.
  29. Verify that the black release lever of the drive unit HV harness connector is in the open position, install the connector flat and square to the drive unit inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  30. Remove the leak test adapter plug from the drive unit inverter logic connector.
  31. Connect the electrical harness to the drive unit inverter logic connector, and then secure the locking tab.
  32. If the air leak test was performed on the front drive unit inverter, install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  33. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  34. Connect LV power. See LV Power (Disconnect and Connect).
  35. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  36. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.